Method and apparatus for acoustic data transmission in a subterranean well

ABSTRACT

The disclosure describes a method and apparatus for effectively communicating data along an acoustic transmission path. The method comprises driving an acoustic transmitter to send a data signal along the acoustic transmission path, where the signal is distorted by ambient noise. The distorted signal is input to a spaced apart plurality of sensors so that consequent time-delayed signals provide reinforcement of the basic signal and attenuation of the ambient noise component when combined.

PRIORITY CLAIM

This application is a divisional of and claims priority to U.S. patentapplication Ser. No. 12/256,352, filed on Dec. 3, 2008, entitled METHODAND APPARATUS FOR ACOUSTIC DATA TRANSMISSION IN A SUBTERRANEAN WELL, andU.S. patent application Ser. No. 11/633,264, filed Dec. 4, 2006,entitled “METHOD AND APPARATUS FOR ACOUSTIC DATA TRANSMISSION IN ASUBTERRANEAN WELL”, now issued as U.S. Pat. No. 7,508,734.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

REFERENCE TO MICROFICHE APPENDIX

Not applicable

TECHNICAL FIELD

The present invention pertains to a system for transmitting acousticdata in an oil well environment and more particularly, to use ofmultiple sensors for reinforcement of the transmitted signal andattenuation of ambient noise.

BACKGROUND

Interest has increased in transmitting acoustic signals to and fromlocations in an oil well environment. The basic operating principal inacoustic signal transmission in a tubular media is to impart propagatingstress-strain waves into a pipe or tubing string which travel within thepipe to a distant location where transducers detect the signal which isthen interpreted by the receiving equipment. In this way, data andsignals can be transmitted via mechanical tubular transmission channelssuch as pipe or tubing.

There are practical problems in the transmission of acoustic signals.When tubing, drill pipe or casing is used as an acoustic transmissionchannel, significant signal distortion often occurs, due to reflectiveinterfaces in the channel such as tool joints, collars or other upsets.Additionally, there can be significant attenuation and interferenceassociated with the fluid system contained in the wellbore and echoes ofthe acoustic signals themselves within the wellbore. The receiver issubjected to noise from the operation of surface equipment and otherexternal disturbance sources, as well as from fluid flow and other noisepresent in the acoustic channel. These factors significantly reduce theconditions under which acoustic data transmission may be effectivelyutilized. Acoustic data transmission may be limited by the distance ofthe transmission, the number and type of upsets in a drill string.

Efforts to effectively transmit data acoustically have often centered oncareful control of the frequency and bandwidth of the transmission, thetiming of the transmission and the duration of the transmission. U.S.Pat. No. 3,252,225 issued to Hixon and U.S. Pat. No. 4,314,365 issued toPetersen teach selection of transmission wave length based upon pipecharacteristics such as the length of pipe sections and the overalllength of the drill string. U.S. Pat. No. 4,390,975 issued to Shawhansuggests delaying successive acoustic data transmissions to allowreflections of earlier transmissions to dissipate. Similarly, U.S. Pat.No. 5,050,132 issued to Duckworth discloses transmissions of acousticdata signals only during pre-selected short time intervals to avoid datadistortion. U.S. Pat. No. 5,124,953 issued to Grosso discloses selectinga passband frequency for acoustic data transmission that best correlatesa measured and a modeled spectral density of the acoustic transmission.U.S. Pat. No. 5,148,408 issued to Matthews similarly suggests thetesting and finding of an optimum frequency for acoustic datatransmission which results in the most efficient reception of theacoustic data under the circumstances then present in the well. TheMatthews patent suggested period testing of data transmission throughthe drill string during drilling operations, finding an optimumfrequency for transmission based upon drill string conditions at thetime of testing, and changing the acoustic data transmission frequencyas needed. U.S. Pat. No. 4,562,559 issued to Sharp et al, proposes aphase-shifted transmission wave having a broader frequency spectrum tobridge gaps in the passband frequencies. U.S. Pat. No. 5,128,901 issuedto Drumheller proposes transmission of acoustic data conditioned tocounteract interference caused by the drill string so as to enhance datatransmission.

In some systems it is possible to model a communication channel beforethe system is placed in service and design an acoustic transmitter tocompensate for the channel distortion. However, in an oil well,complexities of the acoustic transmission environment change constantly,defying any attempt to design a workable static acoustic transmitter. Areceiver embodying a single sensor must accomplish all of the noisereduction in the electronics.

From the foregoing, it is apparent that a need exists for improvedmethods of acoustic data transmission and, in particular, a need existsfor improved methods of acoustic data transmission in oil wellenvironments. Furthermore, it would be most desirable to provide suchmethods for reinforcement of the basic control signal and attenuation ofunwanted interference. If the noise is high, it can swamp the availablesignal. Thus, it is particularly desirable to have a method of reducingthe noise prior to the digitization of the signal so as to increase therange and reliability of acoustic data transmission.

SUMMARY

The present invention describes methods and apparatus for effectivelycommunicating data along the acoustic transmission path of asubterranean well. The method comprises driving an acoustic transmitterto send a data signal along the acoustic channel where the signal isdistorted by ambient noise. The distorted signal is input to a pluralityof sensors, with the sensor output then being combined. Signal timedelays, imposed either before or after sensing, condition the signal soas to reinforce the basic signal and attenuate ambient noise whencombined.

In a preferred embodiment of the present invention, a conventionalacoustic transmitter is used along with a phased array utilizing aplurality of sensors. The sensors are placed at spaced apart locationsalong the drill string. The pre-selected and known distance betweensensor locations is divided by the speed of acoustic propagation of thechosen signal frequency (f) to indicate the time shift, or delay, to beimposed on the acoustic signals as measured by the sensors. A signalsent from the transmitter as an acoustic pulse travels along theacoustic transmission path, accompanied and distorted by the addition ofambient noise, and is sensed at spaced intervals by each of the sensors.Then, combining time delayed sensor outputs, by addition ormultiplication, provides a reinforced signal at the receiver. Inasmuchas the ambient noise is “off-frequency”, it is not reinforced in asimilar manner and is relatively diminished at the receiver.

In another preferred embodiment of the present invention utilizingspatial filters, the transmitter is encoded to provide an outputconsisting of a summation of the basic signal and varying time-delayversions of that transmitted signal. The time delay between the basicsignal and each subsequent time-delayed signal equals the time it takesto pass between the sensors at the receiver. The result is that thebasic signal arrives at the most distant sensor at the same time thateach time-delayed signal arrives at each sensor nearer to the source.Spatial filtering results in the transmitted signal being reinforced andmagnified in amplitude whereas the magnitude of uncorrelated ambientnoise will decrease.

Another preferred embodiment of the present inventions utilizes adaptivetechniques and multiple sensors to reduce the effects of ambient noiseon data transmission in an oil well environment. A sensor is added tothe receiver input to measure a reference noise in order to help cancelor reduce the effects of ambient noise received at the receiver inputsensors. The sensor for measuring the reference noise typically may beplaced out of the direct transmission path, at a location that wouldfeature a reduced signal from the transmitter. The noise reference isgiven a frequency weight and then subtracted from the measured sensorsignal. The frequency weights account for the frequency response of thetransmission path between the noise reference and the sensors andtypically apply a gain and phase that changes with frequency. Adaptivetechniques, such as the adaptive feed-forward technique, may be utilizedto allow adaptation to changes in the transmission path.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated into the specification toassist in explaining the present invention. The drawings illustratepreferred and alternative examples of how the invention can be made andused and are not to be construed as limiting the invention to only thoseexamples illustrated and described. The various advantages and featuresof the present invention will be apparent from a consideration of thedrawings in which:

FIG. 1 shows the general arrangement of acoustic telemetry components inan oil well;

FIG. 2 is a schematic view of a time delay circuit which may be used inthe present inventions;

FIG. 3 is a schematic view of a first preferred embodiment of thepresent inventions;

FIG. 4 is a schematic view of a second preferred embodiment of thepresent inventions; and

FIG. 5 is a schematic view of a third preferred embodiment of thepresent inventions.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention teaches a method for reinforcing an acousticsignal transmitted in an oil well environment, while suppressingunwanted noise, and is described in the following by referring todrawings of examples of how the invention can be made and used. In thesedrawings, reference characters are used throughout the views to indicatecorresponding components. The embodiments shown and described herein areexemplary. Some details are well known in the arts, and as such may beneither shown nor described.

FIG. 1 is a representational view of a typical subterranean drillingapparatus 10. Drilling rig 12 operates to support a drill string 14. Thedrill string 14 and the well bore 28 comprise an acoustic channel ortransmission path 15. Acoustic transmission path 15 can include greateror fewer elements, depending on the drilling, testing or productionoperations underway and may include well parts or tools present at thetime. The drill string 14 is made up of pipe sections 16 connectedtogether by tool joints 18. The drill string 14 is used for operationswithin a wellbore 28 which may be cased along portions of its length.Depending on the circumstances at the well site, the drill string 14 mayinclude valves 30 and 32, packers 34, subassemblies, collars or otherupsets. The apparatus herein may be utilized during any well operations,including drilling, testing, completion and production. FIG. 1 showscommunication units 20, 22 and 24 which may be placed on, in or near thedrill string 14, below, at or above the surface 26, as shown. Thecommunication units 20, 22 and 24 may be utilized for transmittingand/or receiving acoustic signals to and from locations within well bore28. For example, communication unit 20 may transmit acoustic signalsutilizing the methods described herein, to a receiver at communicationunit 24.

FIG. 2 is a schematic view of the circuit of an analog op-amp constanttime delay module 33 using a CLC428 linear integrated circuit 35, whichmay be used in subsequently disclosed embodiments of the presentinventions. The signal input A is the same as the signal output A′ buttime-delayed by a designed period as determined by selected values of Cand R. This circuit can be adapted to provide different time-delays byselecting other values of R and C, where the time-delay equals 2RC. Thecircuit, as illustrated, with Rg and Rf each having a value of 249 Ohms,a C value of 63 pF and a R value of 95.3 Ohms will impose a constanttime-delay of approximately 0.5 milliseconds across the given frequency.

The time delay circuit can be utilized to provide constant time delayacross the frequency of interest. In an analog circuit, constant timedelay can be accomplished by providing linear roll-off in phase asfrequency increases. The time delay circuit may utilize a first orderPade approximation of the Laplace transform of an ideal time delay.Higher-order Pade approximations of the Laplace transform can be used ifa wider frequency response is needed or if more accuracy is desired.

FIG. 3 shows a preferred embodiment of the present invention utilizing aphased-array to reduce the effects of ambient noise on a transmittedsignal in an oil well environment. A conventional communication unit 40is used as a transmitter together with a plurality of sensors 42 a, 42b, 42 c and 42 d. The sensors are placed at spaced apart locations alongthe acoustic transmission path 15. The signal frequency may be chosenfor being out of the general range of noise from the operation ofsurface 7 equipment and other external and internal disturbance sources.The distance between locations of the receiver sensor 42 ispredetermined and the speed of acoustic propagation (Vp) of the chosensignal frequency (f) is known. The time delay imposed on the signals asmeasured by the receiver sensors 42 can be calculated by dividing thedistance between the sensors 42 by the speed of the acoustictransmission. The sensors 42 are preferably placed equidistant from oneanother, however any arrangement with known distances between thesensors is adequate. Three or more sensors will generally be used and,since the rate of acoustic propagation Vp in the acoustic medium, suchas through steel, is known, the time delayed applied to the sensoroutputs can be calculated.

A signal sent from transmitter 40 as acoustic pulse 50, or s(t), travelsalong the acoustic transmission channel 15, accompanied and distorted bythe addition of ambient noise N(t). Acoustic pulse 50 is sensed alongwith channel ambient noise N(t) by each of the sensors 42 a, 42 b, 42 cand 42 d. Since sensor 42 a is closest to the transmitter 40, its outputto receiver 48 is ahead of the output of sensors 42 b-d. The output fromthe sensors 42 are weighted by time delay weights 44. The time-delay(dt) is weighted as determined by the distance between the sensors 42.Preferably the sensors 42 are spaced equidistant from one another,simplifying the weights to multiples of (dt), such as (dt), 2(dt), 3(dt). . . n(dt). However, other arrangements of sensors 42 may be used. Thetime delayed sensor outputs are combined 45 by multiplication orsummation. The combined signal, or receiver signal 48, is effectivelynoise filtered. Inasmuch as ambient noise N(t) is non-correlated, it isnot reinforced in a similar manner and is relatively diminished in thereceiver signal 48. A greater number of sensors may be used to achieveeven stronger signal reinforcement, the number being limited only bypractical considerations.

FIG. 4 is a schematic view of a second preferred embodiment of thepresent invention utilizing spatial filters to reduce the effects ofambient noise on a data transmission in an oil well environment. Anarray of sensors 42 a, 42 b, 42 c and 42 d are employed in a receiver 48at spaced apart locations along the acoustic transmission channel 15.Unlike in the phased array described above, with a spatial filter thetransmitter 40 encodes the output signal 50 or s(t). The output signal50, or a(t), of the transmitter 40 consists of a series 53 of thetransmitted signal 50 a, or s(t), and varying time delayed versionsthereof, 50 b, 50 c and 50 d, or s(t+dt), s(t+2dt) and s(t+3dt),respectively. In practice, the delayed signals may be transmitted with asmall enough time delay that the signals 50 a-d overlap to some degree.Where the signals overlap, the acoustic transmission is represented as asummation of the signals. The time delay between the signals is selectedto correspond to the distances between the receiver sensors 42 such thatwhen the first transmitted signal 50 a reaches the sensor 42 d furthestfrom the transmitter, each of the later-sent signals 50 b-d, arrive at acorresponding sensor, 42 c, 42 b and 42 a, respectively.

In the example explained above, the sensors 42 a-d are placedequidistant from one another, such that the time delays of the varyingsignals 50 b-d are simply multiples of the same time delay, (dt). Otherarrangements of sensors may be employed with the time delays betweensignals 50 spaced apart appropriately such that the transmitted signals50 arrive at corresponding sensors 42 at the same time.

During transmission of the signal 50, ambient noise N(t) in the channel15 is added to and interferes with the transmitted signal. The sensors42 a-d at the receiver 48 sense the arriving signals 50 a-d. Thereceived signals 50 a-d are then combined 45, typically by summation, atthe receiver for a resultant received signal R(t). The spatial filteringof the transmitted signal results in the reinforcement and magnificationof the amplitude of the signal. The magnitude of the transmitted signalincreases linearly with the number of sensors 42 utilized in thereceiver 48. Meanwhile, uncorrelated noise, such as ambient noise N(t)in the acoustic channel 15 is reduced in amplitude as it is“off-frequency” with the transmitted signal 50. The magnitude ofuncorrelated noise N(t) is decreases by one over the square root of thenumber of sensor elements 42 in the receiver 48. Uncorrelated noises,such as pump, sand, flow and other noises, will be reduced utilizing thespatial filter.

A problem with spatial filters is the potential for reflectedtransmitted signals to arrive at the sensors 42 simulating thetransmitted signal 50. Such reflected signals are correlated noise. Ifan evenly weighted spatial filter is used, then reflected transmissionsignals are sensed equally with the intended transmission signal 50. Thereflected signal is, of course, sensed in the reverse pattern from thetransmitted signal 50. That is, for an equally-spaced array, the signal50 a is received at the sensor 42 a closest to the transmitter 40 at thesame time that each subsequent signal 50 b-d is received at sensors 42b-d, respectively.

The problem of reflected signals is solved by unevenly weighting thetransmitted signals 50 a-d. With unevenly weighted signals 50 a-d anduneven weighting of the sensors 42 a-d, the reflected signal will notmatch the pattern of the transmitted signal. As a result, the spatialfilter can be used to cancel the reflected signal. For example, sensors42 a-d may be utilized and the transmitted signal sent as time delayedsignals 50 a-d. The sensors 42 a-d are weighted (W) prior to combinationas [−1 1 1 1]. The time delayed signals 50 a-d are amplitude weightedprior to transmission according to the pattern [−1 1 1 1]. The primarysignal, signals 50 a, 50 b, 50 c, and 50 d, arrive simultaneously atrespective sensors 42 d, 42 c, 42 b and 42 a. The measured output of thereceiver 48 is the product of the sensor weights [−1 1 1 1] and thetransmission weighted amplitude [−1 1 1 1]. The resulting measuredsignal has an amplitude of 4, calculated as ((−1×−1)+(1×1)+(1×1)+(1×1)).

The reflected signal will have the reverse weighting and willeffectively be cancelled upon summation of the weighted sensor signals.Using the same example, the reflected signal will arrive such thatsignals 50 a, 50 b, 50 c, and 50 d arrive simultaneously at respectivesensors 42 a, 42 b, 42 c, and 42 d. As a result, when the reflectedsignals hit the sensors, the measured output at the receiver 48 is theproduct of [−1 1 1 1] and the sensor weights [1 1 1 −1], for a measuredsignal amplitude of zero, calculated as ((−1×1)+(1×1)+(1×1)+(−1×1)).

Such uneven weighting of the spatial filter requires at least threesensors and corresponding signal components to cancel the reflectedsignal upon summation. The sensor weights or the transmission weightsmay have differing magnitudes, which are necessary if a 4-sensorreceiver is utilized. However, there is no theoretical upper limit tothe number of sensors utilized at the receiver. Practitioners willrecognize that the same result can be reached through use of a singlesensor receiving a series of time delayed signals with summation of thereceived time-delayed signals occurring at the receiver processor. Ineffect, it is possible to apply time delays at both the transmitter andreceiver.

FIG. 5 shows another preferred embodiment of the present inventionsusing multiple sensors and an adaptive filter. FIG. 5 showscommunication transmission unit 40, with acoustic signal 50 sent toreceiver 48 distorted by unwanted noise sources N(t) added along theacoustic transmission path 15. An adaptive filter utilizes anoise-sensing sensor 44 to measure a reference noise signal N_(R)(t) toreduce the effects of ambient noise received at the receiver 48.

Reference noise sensor 44 is added, typically someplace either out ofthe direct transmission path of the transmitted signal 50 or between thereceiver 48 and the source of the noise. Typical reference noise sensor44 placements include above the slips, above the Kelly, above theinjectors, or any other place that would feature a reduced signal fromcommunications unit 40. Sensor 44 detects a noise reference signalN_(R)(t), which is given a frequency weight (W) at the receiverprocessor and subtracted from the received signal from the sensor 42.The frequency weight (W) accounts for the frequency response of thetransmission path between the noise reference and the sensors andtypically apply a gain and phase that changes with frequency. Thesummation 45 of the received signal from the sensor 42 and thenoise-reference sensor 44 result in a receiver signal R(t) whicheffectively reduces the effects of ambient noise on the transmittedsignal 50.

Standard techniques for calculating the frequency weights includenumerical modeling, measuring the transfer function, adaptivefeed-forward control, and neural networks. Feed-forward techniques areespecially appealing because they can adapt to changes in the ambientnoise along the transmission path.

The techniques described herein can be utilized individually or combinedfor more effective noise reduction. Additionally, the techniquesdescribed herein teaches filtering techniques including time weights anddelays. It is apparent to those skilled in the art that other filters,such as FIR, IIR, state space, non-linear, and sliding mode filters maybe utilized to produce a more advanced telemetry system capable of noisecancellation.

The embodiments shown and described above are exemplary. It is notclaimed that all of the details, parts, elements, or steps described andshown were invented herein. Even though many characteristics andadvantages of the present inventions have been described in the drawingsand accompanying text, the description is illustrative only. Changes maybe made in the detail, especially in matters of arrangement of the partsor steps within the scope and principles of the inventions. Therestrictive description and drawings of the specific examples above donot point out what an infringement of this patent would be, but are toprovide at least one explanation of how to use and make the inventions.The limits of the inventions and the bounds of the patent protection aremeasured by and defined in the following claims.

1-8. (canceled)
 9. A method of data transmission in an oil wellenvironment, the method comprising the steps of: providing an acoustictransmitter and an acoustic receiver, the transmitter and receiverspaced apart along an acoustic transmission channel; sending a pluralityof transmitted signals from the transmitter, along the acoustic channel,where the transmitted signals are joined by ambient noise travelingalong the acoustic channel; providing at least one sensor at thereceiver, the at least one sensor for sensing and creating a pluralityof sensor signals corresponding to the plurality of transmitted signals;sensing the transmitted signals and ambient noise at the sensor, thesensor providing corresponding electrical output signals; and combiningthe sensor output signals to provide a receiver signal, thereby reducingthe effect of ambient noise on the transmitted signals.
 10. The methodof claim 9 wherein the electrical output signals are weighted prior tocombining.
 11. The method of claim 9 wherein the plurality oftransmitted signals are weighted prior to sending them along theacoustic channel.
 12. The method of claim 10 wherein the plurality oftransmitted signals are weighted prior to sending them along theacoustic channel.
 13. The method of claim 12 wherein the weights on theoutput signal or the weights on the transmitted signals arereconfigurable.
 14. The method according to claim 9, wherein the atleast one sensor comprises a plurality of spaced apart sensors.
 15. Themethod according to claim 9, wherein the acoustic signal is transmittedat one or more selected frequencies and further comprising the steps of:placing a noise-reference sensor proximate to the acoustic channel;sensing ambient noise at the noise-reference sensor, the noise-referencesensor providing a corresponding electrical signal; weighting theelectrical noise-reference signal; combining the weighted electricalnoise-reference signal with the measured sensor output.
 16. A method ofdata transmission in an oil well environment, the method comprising thesteps of: providing an acoustic transmitter and an acoustic receiver,the transmitter and receiver spaced apart along an acoustic transmissionchannel; sending an acoustic signal from the transmitter at one or morechosen frequencies, along the acoustic channel, where it is joined byambient noise traveling along the acoustic channel; providing at leastone sensor at the receiver for sensing the transmitted signal andambient noise in the channel, the sensor providing a correspondingelectrical sensor output signal; providing a noise-reference sensor forsensing the ambient noise in the channel, the noise-reference sensorproviding a corresponding electrical noise-reference output signal; andcombining the output signals to provide a receiver signal, therebyreducing the effect of ambient noise on the transmitted signal.
 17. Themethod of claim 16 where the signal from the noise reference sensor isweighted.
 18. The method of claim 17 wherein the weight applied to thenoise reference sensor is reconfigurable.
 19. The method of claim 16,further comprising providing a plurality of spaced apart sensors at thereceiver, the sensors provided along the length of the acoustic channelat a first and at least one subsequent location; sensing the transmittedsignal and ambient noise at the plurality of sensors, the sensorsproviding corresponding electrical output signals; and combining thesensor output signals and noise-reference output signal to provide areceiver signal.
 20. The method of claim 16, further comprising sendinga plurality of transmitted signals from the transmitter, along theacoustic channel, where the transmitted signals are joined by ambientnoise traveling along the acoustic channel; providing a plurality ofspaced apart sensors at the receiver, the plurality of sensorscorresponding to the plurality of transmitted signals and spaced alongthe length of the acoustic channel such that the transmitted signalsarrive simultaneously at corresponding sensors; sensing the transmittedsignals and ambient noise at the plurality of sensors, the sensorsproviding corresponding electrical output signals; and combining thesensor output signals and noise-reference output signal to provide areceiver signal.